Laying Nest with Rack Drive Floor Expulsion System

ABSTRACT

This invention relates to laying nest having a rack drive expulsion system. As disclosed herein, the invention preferably comprises a laying nest for hens comprising a box and a rack drive floor expulsion system. The floor pivotably moves between first and second positions by virtue of a gear rack that is fixedly connected to and disposed within the box, and a gear wheel that is rotatably connected to the floor. Accordingly, the expulsion system provides for the selected removal of hens from the laying nests as desired.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and the benefit of, U.S.Provisional Patent Application Ser. No. 62/451,500 filed on Jan. 27,2017.

FIELD OF THE INVENTION

This invention relates to a laying nest having a rack drive expulsionsystem. In general, an expulsion system provides for the selectedremoval of hens from the laying nests as desired. Typically this removalis accomplished in the evening so that the hens cannot sleep in the egglaying nests at night.

BACKGROUND OF THE INVENTION

Known expulsion systems include a torsion expulsion system and a gearrack expulsion system. As shown in FIGS. 1 and 2, the gear rack systemis typically a system comprising a drive shaft 1 arranged in a fixedposition, which is provided at several positions with gear wheels 2fixedly connected with the drive shaft 1. The gear wheels 2 engage gearracks 3 associated with them. The gear racks 3 are connected by one endto the bottom 4 of the box 7 of the laying nest 6. The bottom 4 ispivotally arranged and can be pushed by the gear rack 3 from asubstantially horizontal position to a substantially vertical positionupon rotation of the drive shaft 1. As a result, hens that have enteredthe laying nest 6 cannot continue sitting in the box 7. FIGS. 1 and 2respectively show a perspective view and a side elevational view of anexemplary prior art laying nest 6 with a typical gear rack 3 expulsionsystem.

As shown in FIG. 3, a typical prior art torsion expulsion systemcomprises an expulsion plate 7 a, b which is fixedly mounted to a tube8. The tube 8 is in a fixed position and is rotatable about its axis. Assoon as the tube 8 is rotated, the expulsion plate 7 a, b pivots alongwith it and pushes hens out of the system. FIG. 3 shows a sideelevational view of an example of the torsion system. In that examplethe expulsion plate 7 a, b is designed in two parts 7 a, 7 b which arepivotable relative to each other. Through this construction, an opening(via which eggs laid by the hens roll from a box 9 to the egg conveyor)is not blocked by the expulsion plate 7 a, b when the latter is situatedin a position against a back wall of the box 9, as shown in theleft-hand box 9 of FIG. 3. As shown in the right-hand box 9 of FIG. 3,the expulsion plate 7 a, b is shown in an intermediate position and inan end position.

The Netherlands Patent Number 9,301,627 describes a hybrid expulsionsystem, which is a combination of a gear rack system and a torsionsystem, whereby a drive shaft arranged in a fixed position is providedwith gear wheels which are engaged by movably arranged gear racks. Thegear racks have one end indirectly connected to a pivotally arrangedexpulsion plate.

U.S. Pat. No. 9,510,567 (the “'567 patent”), which is also owned by theassignee of the present application, addresses some of the shortcomingsof earlier prior art expulsion systems. For example, one associatedproblem with the gear rack expulsion system is that it needs to lift thefull weight of all hens plus the bottoms of the nests to drive the hensout of the boxes of the laying nests. This requires a heavy-duty drive,which is unfavorable from a cost perspective. Moreover, the bottoms andthe gear racks need to be of a relatively heavy-duty design to be ableto resist the forces occurring upon upward pivoting of the bottoms andthe chickens present thereon. Also, some prior art gear rack systemswith a movable rack include a design wherein the rack extends below thebox (e.g., see FIGS. 1 and 2) and thus minimizes the ability to stackmultiple boxes together in a space-efficient manner due to the fact thatthe rack was disposed at least part of the time outside of the nest andbox.

As shown and described in the '567 patent, FIG. 4 shows a perspectiveview of a laying nest 10 with an expulsion system shown therein. Thelaying nest 10 comprises boxes 12 having at least a bottom 24, sidewalls18, a back wall 22, and a roof 20. The bottoms 24 of the boxes 12 aredisposed so as to slope to some extent, so that eggs upon being laidroll automatically to the lowest point of the bottom 24 and aredischarged from the respective box 12 to a collecting space 16. Ingeneral, such a collecting space 16 is provided with a conveyor belt orchain conveyor with the aid of which the eggs can be conveyed to an endof the laying nest 10 for further processing. The collecting space 16 isnot accessible to the hens. As further shown in FIG. 4, a sidewall 18 ofthe collecting space 16 is omitted in order to make somewhat more detailof the laying nest 10 visible. In the example shown, there are twoseries of boxes 12, each adjoining the single collecting space 16. Thelaying nest 10 is provided with an expulsion system for driving the hensout of the boxes 12. This is desirable, for instance at night, toprevent soiling of the boxes 12 by the hens.

The expulsion system of the '567 patent is shown in more detail in FIGS.5-10. As shown, the expulsion system comprises at least one shaft 26,which is provided with at least one gear wheel 28, which is fixedlyconnected with the shaft 26. Further, the expulsion system comprises atleast one expulsion plate 30 which is rotatably connected with the shaft26. The expulsion plate 30 is further pivotally and slidably connectedvia a support shaft 32 with the box 12. To that end, the sidewalls 18are provided with a vertical slot 36 in which the support shaft 32 isreceived. This expulsion system further comprises at least one gear rack34 which is fixedly disposed in the box 12, and which is configured forcooperation with the above-mentioned gear wheel 28, such that uponrotation of the shaft 26 the gear wheel 28 moves along the gear rack 34,thereby carrying along the expulsion plate 30. In the example shown inFIGS. 5-10, the gear racks 34 are each connected with an associatedsidewall 18. It is also possible, however, that the gear racks 34 areconnected with a frame part of the laying nest 10.

FIG. 7 shows a side elevation of the example of the laying nest 10represented in FIG. 4, with omission of the sidewall 18 of theright-hand series of boxes 12. Clearly visible is the expulsion plate 30which is a first end position. In this first end position the hens canreach the bottom 24 of the boxes 12 via an entrance opening 42.

FIG. 8 shows detail VIII from FIG. 7, with the expulsion plate 30 in thefirst end position.

FIG. 9 shows a similar detail to detail VIII, but now it is clearlyvisible that the shaft 26 has moved along the gear rack 34 to the rightand the expulsion plate 30 is in an intermediate position. Also, it isclearly visible that the support shaft 32 has moved up in the slot 36.Further, it is clear that a lower edge 30 a of the expulsion plate 30 issituated closely above the bottom 24. Accordingly, the hens cannot slipthrough between the lower edge 30 a and the bottom 24. Also, dead henswill be shoved off the bottom 24 by the expulsion plate 30.

FIG. 10 shows that the expulsion plate 30 is in a second end position.The lower edge 30 a of the expulsion plate 30 now adjoins an upper edge38 of a front wall 40 of the box 12, which bounds the entrance opening42 for the hens to enter the box 12. The hens now cannot reach thebottom 24 anymore and have been driven out of the box 12. It is clearlyvisible that in the second end position the shaft 26 with the gear wheel28 has moved all the way to the right. The support shaft 32 now sits atthe bottom of the slot 36 again.

The expulsion plate 30 of the laying nest 10 may be designed as a wiremesh mat. A wire mesh mat consists of metal bars which are mutuallyconnected. Thus, the bars may, for instance, extend perpendicularly toeach other and be interconnected by welding. The mutual distance betweenthe parallel bars can be in the range of, for instance, 5-10 centimeters(“cm”) so that the openings between the bars cannot be passed by thehens. Instead of being implemented as a wire mesh mat, the expulsionplate 30 may also be formed by a plank of plastic or wood. The expulsionplate 30 need not necessarily be of a planar design. It is also possiblethat the expulsion plate 30 is of a curved design or does not have auniform thickness throughout.

The '567 patent also addresses a shortcoming of prior art torsionsystems (see FIG. 3) where a lower edge of the expulsion plate duringthe pivoting movement is at such a large distance from the bottom of thebox that the possibility of chickens passing under the edge and thenremaining behind in the box cannot be precluded. Also, that system doesnot always manage to remove dead hens from the box because of this gapbetween the expulsion plate and the bottom of the box.

In view of the prior art, there exists a need for a laying nestexpulsion system that reliably and effectively removes hens from thelaying nest as desired, wherein the system comprises fewer moving parts,requires less operating (drive) power, is highly versatile (i.e,stackable), and provides for improved desoiling of the system,particularly the system floor.

SUMMARY OF THE INVENTION

To meet the needs described above, the present disclosure provides alaying nest with a rack drive expulsion system comprising:

A laying nest for hens comprising:

a box having a bottom, sidewalls, a back wall, and a roof, wherein thebox is configured to house hens and eggs;

an expulsion system that is configured to remove the hens from the box,wherein the expulsion system comprises:

a floor;

a first shaft provided with a gear wheel having a plurality of teeth,the gear wheel being fixedly connected with the first shaft;

a gear rack having a plurality of teeth that correspond to the teeth ofthe gear wheel; and

a second shaft having an axis;

wherein the floor is both rotatably connected with the first shaft andpivotably connected with the box via the second shaft;

wherein the gear rack is both fixedly arranged in the box and configuredfor cooperation with said gear wheel;

wherein upon rotation of the first shaft, the first shaft moves along apath extending parallel to the gear rack, thereby pivotably moving thefloor by virtue of the first shaft moving along the path extendingparallel to the gear rack and the second shaft pivoting around the axis.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a prior art laying nest comprising agear rack expulsion system.

FIG. 2 shows a side elevational view of the prior art laying nest ofFIG. 1.

FIG. 3 shows a side elevational view of a prior art laying nestcomprising a torsion expulsion system.

FIG. 4 shows in perspective view of another example of a prior artlaying nest having an expulsion system with a rack disposed inside thenest area.

FIG. 5 shows detail V of the prior art FIG. 4.

FIG. 6 shows detail VI of the prior art FIG. 4.

FIG. 7 shows a side elevational view of the prior art FIG. 4, with asidewall of the right-hand box removed for clarity.

FIG. 8 shows detail VIII of the prior art FIG. 7 with the expulsionplate in a first end position.

FIG. 9 shows a view similar to detail VIII of the prior art FIG. 7, theview showing the expulsion plate in an intermediate position.

FIG. 10 shows a similar view to detail VIII of the prior art FIG. 7, theview showing the expulsion plate in a second end position.

FIG. 11 shows a side elevational view of a laying nest having a rackdrive floor expulsion system provided in accordance with a preferredembodiment of the present invention, with a sidewall of the right-handbox removed for clarity, the floor of the expulsion system being shownin a downward orientation.

FIG. 12 shows a side elevational view of the laying nest shown in FIG.11, with a sidewall of the right-hand box removed for clarity, the floorof the expulsion system being shown in an upward orientation.

FIG. 13 shows a side elevational view of detail A of FIG. 12.

FIG. 14 shows a perspective view similar to detail A of FIG. 12.

FIG. 15 shows an alternative perspective view similar to detail A ofFIG. 12.

DETAILED DESCRIPTION OF THE EMBODIMENTS

While the present invention may be susceptible to embodiment indifferent forms, there is described herein in detail, specific preferredembodiments with the understanding that the present disclosure is to beconsidered an exemplification of the principles of the invention, and isnot intended to limit the invention to that described herein.

The rack drive floor expulsion system provided in accordance withpreferred embodiments of the present invention overcomes the abovedescribed problems associated with prior art torsion and gear rackexpulsion systems. For example, advantageously, the design of preferredembodiments of the present system allow for the optimization of overallsystem height because no space is lost underneath the nesting and boxareas because the racks are disposed in a manner such that they do notoccupy space below the nest, nor do they protrude therefrom. Moreover,the present system is a novel and inventive rack drive floor expulsionsystem that comprises fewer moving parts, requires less operating(drive) power, and provides for improved desoiling of the system,particularly the system floor.

The expulsion system of the present invention is optionally designed foruse with a laying nest system as previously shown and described withreference to the '567 patent and FIG. 4, as will be appreciated by oneof ordinary skill in the art.

A laying nest which may also be used with the present rack drive floorexpulsion system is shown in FIGS. 11 and 12. As shown in FIGS. 11 and12, a laying nest 100 with rack floor expulsion system is provided inaccordance with preferred embodiments of the present invention. Thelaying nest 100 comprises boxes 112 having a bottom 124, sidewalls 118,a back wall 122, a roof 120. The nest 100 further comprises a floor 130.In a preferred embodiment of the present invention, the floor 130 isimplemented as a wire mesh mat. The floor 130 of the box 112 is disposedso as to slope to some extent, so that eggs upon being laid rollautomatically to the lowest point of the floor 130 and are dischargedfrom the respective box 112 to a collecting space 116. The box 112defines an opening 140 configured to allow the eggs to roll out of thebox 112 into the collecting space 116. The box further defines a frontopening 150 where hens will enter and exit the box 112. In general, sucha collecting space 116 is provided with a conveyor belt or chainconveyor with the aid of which the eggs can be conveyed to an end of thelaying nest for further processing. The collecting space 116 is notaccessible to the hens. As shown in FIGS. 11 and 12, a sidewall 118 ofthe collecting space 116 is omitted in order to make somewhat moredetail of the laying nest 100 visible.

The rack drive floor expulsion system of the present invention is shownin more detail in FIGS. 13-15 and comprises at least one shaft 126,which is provided with at least one gear wheel 128, which is fixedlyconnected with the shaft 126. Further, according to an important aspectof the present invention, the underside of the floor 130 is rotatablyconnected with the shaft 126 by one or more of downwardly extendingsupports 125. The floor 130 is further pivotably connected via a supportshaft 132 with the box 112. The support shaft 132 is also rotatablysupported on the underside of the floor 130 away from the shaft 126 asshown in FIG. 15. The sidewalls 118 are also provided with an opening inwhich the support shaft 132 is rotatably received.

The expulsion system further comprises at least one preferably arcuategear rack 134 which is fixedly disposed in or on the box 112 and whichis configured for cooperation with the above-mentioned gear wheel(s)128, such that upon rotation of the shaft 126 the shaft 126 moves alongthe gear rack 134, thereby carrying along and pivotally raising thefloor 130 upwardly and about a pivot point. The pivot point is about theaxis of the support shaft 132. In the example shown in FIGS. 11-15, thegear racks 134 are each connected with an associated sidewall 118. Thefloor 130 is pivotably moveable between first and second positions, forexample a tilted horizontal position (see FIG. 11) and an uprightposition (see FIG. 12), wherein the positions may be separated by anapproximately 100 degree angle of rotation. It is contemplated that insome embodiments of the present invention that the gear rack 134 and/orthe gear wheel 128 may be disposed outside the box 112. It iscontemplated that in some embodiments of the present invention that onlyone of the gear rack 134 or the gear wheel 128 may be fixedly attachedto the box 112.

As shown in FIGS. 13 and 14, an arcuate slot 136 is disposed adjacentlyabove and parallel to the gear rack 134. Accordingly, as the shaft 126is rotated and as the gear wheels 128 engage the gear rack 134, theshaft 126 is moved upwardly and arcuately to the right along the pathdefined by the slot 136. As a result, the shaft 126 lifts the floor 130and tilts it up and about the pivot axis defined by the support shaft132 thereby selectively removing the hens from the nest 100 andoutwardly to the right of the box 112.

Unlike prior art systems, the floor 130 acts as the expulsion platethereby making possible an expulsion system with fewer parts. As such,the expulsion system occupies a smaller footprint in the box 112 ascompared with prior art expulsion systems, thereby maximizing space forthe hens nesting therein. Further, with this system, there is no gapassociated with prior art systems between the expulsion plate and thefloor 130 thereby allowing for more efficient and consistent removal ofhens, including deceased birds. The vertical orientation of the floor130, as best shown in FIG. 13, is configured to promote the removal bygravity of detritus from the floor. This aspect aids in the maintenance,cleaning, and sanitation of the floor as compared to prior art systemswhere the bottom or floor of the box remains stationary in asubstantially horizontal position.

As described herein, preferred embodiments of the present inventionrequire fewer moving parts than comparable prior art systems. Forexample, the present invention does not require a slidingly movablesupport shaft as required in the '567 patent.

The invention claimed is:
 1. A laying nest for hens comprising: a boxhaving a bottom, sidewalls, a back wall, and a roof, wherein the box isconfigured to house hens and eggs; an expulsion system that isconfigured to remove the hens from the box, wherein the expulsion systemcomprises: a floor; a first shaft provided with a gear wheel having aplurality of teeth, the gear wheel being fixedly connected with thefirst shaft; a gear rack having a plurality of teeth that correspond tothe teeth of the gear wheel; and a second shaft having an axis; whereinthe floor is both rotatably connected with the first shaft and pivotablyconnected with the box via the second shaft; wherein the gear rack isboth fixedly arranged in the box and configured for cooperation withsaid gear wheel; wherein upon rotation of the first shaft, the firstshaft moves along a path extending parallel to the gear rack, therebypivotably moving the floor by virtue of the first shaft moving along thepath extending parallel to the gear rack and the second shaft pivotingaround the axis.
 2. The laying nest according to claim 1, wherein thefloor is pivotably movable between first and second positions.
 3. Thelaying nest according to claim 2, wherein the first and second positionsare rotationally separated by up to approximately 100 degrees.
 4. Thelaying nest according to claim 2, wherein one of the first and secondpositions is a substantially vertical position, and the floor is therebyconfigured to promote the removal by gravity of detritus from the floor.5. The laying nest according to claim 1, wherein the first shaft islocated between the back wall and the second shaft.
 6. The laying nestaccording to claim 1, wherein the floor is rotatably connected to thefirst shaft by a plurality of supports.
 7. The laying nest according toclaim 1, wherein the floor is rotatably connected with the first shaftby a plurality of supports extending downwardly from the underside ofthe floor.
 8. The laying nest according to claim 1, the box defining anopening configured to allow the eggs to roll out of the box and thefloor being pivotably movable between a first position and a secondposition, wherein when the floor is moving toward the second positionthe floor is moving away from the opening.
 9. The laying nest accordingto claim 1, wherein the floor is implemented as a wire mesh mat.